Refrigeration Tubing Receptacle Box

ABSTRACT

A receptacle box for conveniently and efficiently locating the terminal ends of the refrigeration line set, condensation drain and low voltage wires leading down from an air conditioner unit during initial construction of a building, is disclosed. Specifically, a rectangular box having a top, bottom, angled back, and sides, but open on the front, and having openings on the top through which the line set, condensation drain and low voltage wires can be passed, is disclosed. The receptacle box is mounted in a cutout on the exterior wall of the building before siding is installed.

This application claims priority from U.S. provisional application No. 62/176,084 filed Feb. 4, 2015.

BACKGROUND OF THE INVENTION

The present invention relates to a receptacle box for conveniently and efficiently locating the terminal ends of an air conditioner's refrigeration line set, condensation drain and low voltage wires leading down from the air conditioner unit during initial construction of a building. In particular, the present invention provides a more effective way for the refrigeration line set, condensation drain and low voltage wires to exit from the interior to the exterior of a building without using a fitting or being crushed, kinked or cut off after installation.

When a building such as a home, office building or apartment building is first constructed, and is to have central air conditioning, the air conditioning unit is generally placed on an upper floor, attic space or roof of the building during the early stages of construction. At this time also the air conditioner's refrigeration line set, for compressed refrigerant and return, together with a condensation drain and low voltage electrical line, is connected to the air conditioner unit and leads down to the compressor unit which is placed at a lower level and outside the building. The line set, condensation tube and electrical line must therefore pass from the inside of the building through an outer wall and leave their ends accessible to be connected to corresponding lines coming from the condenser unit, which is installed later.

As is now generally practiced in construction of new buildings, the line set, condensation drain and electrical line exit the wall through a simple hole cut in the wall. This frequently results in one or more of the lines being kinked, which can happen inside the wall, and create a cracked or clogged line resulting in an eventual refrigeration leak. Further, the ends of the lines and tubes are exposed and unprotected which can result in damage to the lines and drains, making it difficult to connect the compressor lines at a later date. Sometimes a fitting is employed to secure the lines on the outside wall, but this does not necessarily solve the problems.

Presently, there is no device or system in use in either private or commercial buildings that provides for the efficient and safe exit of the refrigeration line set, condensation drain and low voltage wires through an external wall that can avoid kinks, cracks and clogs while also protecting the ends while the external wall is being constructed.

SUMMARY OF THE INVENTION

A principle object of the present invention is to provide a device and a method to maintain the integrity of an air conditioner's line set, i.e., the refrigerant tube and return tube, condensation drain and low voltage electrical line, while exiting from an external wall while the building is under construction. It is an object of this invention to prevent kinking, cracking, bending or folding of the refrigeration line set, condensation drain and low voltage wires while exiting the external wall. It is also an object of the present invention to provide a device and a method to protect the ends of the refrigeration line set, condensation drain and low voltage wires once they have exited the wall so that they may be easily connected to the corresponding lines coming from the compressor when that unit is later installed. It is a further object of this invention to eliminate the need for a special exit fitting and to reduce the risk of a refrigerant leak within the external wall.

Thus, according to these objectives, the system of the present invention employs a square or rectangular box that is installed on a new construction building before the siding is installed on the exterior wall. The box penetrates a pre-cut wall cavity so that the refrigeration tubing, condensation drain, low voltage wire, etc., has enough clearance to enter the top of the box which is top-scored for multiple sizes of holes and multiple tubing sets, that are easily cut out with a knife. The box's inner back wall is angled to allow the tubing to gradually exit the box while eliminating the need for a fitting. This configuration also allows the tubing to penetrate the exterior wall of the building without being kinked or crushed, reducing the risk of a refrigerant leak, or of being cut off after installation. The rear angular inner wall also allows water, such as from rain, to run out of the box.

The condensation drain will have a straight run down the inside of the exterior wall of the building which also eliminates the need for a fitting at the exit point of the building where a crack or clog could occur inside the wall. The box also has a flange protruding outwards around the perimeter of the outside lip used as a nail flange for easy and secure installation. The outer lip extends far enough to allow the siding J-bead to be installed around the box and can be sealed weather tight to eliminate any water penetration. This method or installing refrigeration tubing, condensation drains and low voltage wiring saves many hours on installing the system.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring to FIGS. 1-6, filed herewith, for details, dimensions and other specifications.

FIG. 1 is a perspective view of an embodiment of this invention;

FIG. 2 is a front view of a further embodiment of this invention;

FIG. 3 is a top view of the embodiment of FIG. 2;

FIG. 4 is a back view of the embodiment of FIG. 2;

FIG. 5 is a bottom view of the embodiment of FIG. 2; and

FIG. 6 is a side view of the embodiment of FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will now be described with reference to the FIGS. 1-6 of the drawings. Identical elements in the various figures are designated with the same reference numerals.

FIG. 1 illustrates an embodiment of the device of the present invention, configured to accommodate two refrigeration line sets (not shown). The device comprises a box 100 for receiving the ends of a refrigerant tube and return tube (not shown), together referred to as the “line set,” from an air conditioner unit. Box 100 therefore may also be referred to herein as “line set box 100,” Line set box 100 in FIG. 1 is also designed to receive the ends of two condensation drains (not shown), from the air conditioner unit as well as two low voltage electrical lines (not shown), that connect to the air conditioner unit. As shown in FIG. 1, line set box 100 is configured as an open-sided box that can be either square or rectangular in shape. Accordingly, line set box 100 has a top side 105, a left side 110 and a right side 115, a back 120 and a bottom side 125. Where a box would ordinarily have a corresponding “front side” opposite to its back, in line set box 100 the front side opposite back 120 is not present, the front being left open. Thus, line set box 100, having an open side, allows for access to the ends of the refrigeration line set, condensation drain and low voltage line once they have entered the line set box 100 through top side 105.

Constructed of a durable plastic polymer, such as polypropylene, or stamped from an appropriate metal, line set box 100 has a width dimension 130, a height dimension 135 and a depth dimension 140. Although these dimensions can vary according to the size of the line set box desired, for example, when single or multiple line sets are required, in this embodiment the preferred that width dimension 130, which can be between about 4.5″ to about 12″, is about 10″, height dimension 135 which can be between about 10″ to about 14″ is about 11″, and depth dimension 140, which can be between about 3.5″ to about 6″, is about 4.5″. Around the periphery of line set box 100, and towards the front, is located a flange 145 for nailing the line set box to an opening pre-cut into the outer wall 300 of the building (see FIG. 5), prior to the siding being added to the building. Nail flange 145 can be from about 0.5″ to about 2″ wide, and preferably is about 0.75″ wide. Accordingly, nail flange 145 is not placed at the outer edge of line set box 100, but is located about 0.75″ from the rim 150 of line set box 100, to allow space for when the building's siding is added. Thus, when line set box 100 is properly mounted in the pre-cut opening, approximately 0.75″ of the box extends outward from the wall, and the remaining about 3.5″ extends toward the interior of the wall. In addition, rim 150 is configured in the form of a “J-bead” to allow for attachment of trim features that are part of the siding.

FIG. 1 also illustrates the configuration of back 120 and bottom 125, which are not joined at a 90° angle as is typical of an ordinary box. Rather, bottom 125 is angled upward from its leading edge until it meets with back 120, where it is joined. The upward angle 122 of bottom 20 can be generally from about 20° to about 60°, and about 45° is preferred. Being angled in this manner, bottom 125 directs the line set, condensation drain and low voltage line in a gentle are away from back 120 and the building wall, to the outside of line set box 100 and the building itself. In this manner, kinks, cracks and leaks are minimized if not avoided altogether. In addition, the angling of bottom 125 allows for the drainage of water from the box 100, as caused by rain, for example. Once inside of line set box 100, the line set, condensation drain and low voltage lines are “capped” and are thus further protected until the air conditioner compressor unit is installed.

As also illustrated in FIGS. 1, top side 105 contains circular cut-outs 155 which, when removed, allow for the passage of the refrigeration line set and low voltage line into box 100. Cut-outs 155 are comprised of concentric discs 160 and 165, which can be punched out to allow for different diameters of tubing. Generally, the outside disc 160 can have a diameter of about 2.5″ which normally would accommodate the refrigeration line set and low voltage line. The inner disc 165 has a smaller diameter for allowing other size of tubes or wires as desired. Top side 105 may also contain smaller circular cut-outs 170, which are shown as being located between cut-outs 155. This is for purposes of illustration only as cut-outs 155 and smaller cut outs 170 may be located in any desired position on top side 105. Smaller cut-outs 170 are configured as having a smaller diameter than cut-outs 155 and are more particularly designed for the condensation drain and low voltage electrical line. The diameter of smaller circular cut outs 170 may vary, but is preferably about 0.75″.

A further embodiment of the within invention is depicted by FIGS. 2-6, with FIG. 2 being a front view. In this embodiment, line set box 100 is designed for a single air conditioner unit which has only a single refrigeration line set, including low voltage line, and a single condensation drain. Specifically referring to FIG. 3 it can be seen that top 105 of line set box 100 in this embodiment contains only a single cut out 155 for the refrigeration line set and low voltage line, and a single smaller cut out 170 for the condensation drain. Here, however, it can also be seen that smaller cut out 170 may also have concentric discs 175 and 180, so that different size drain tubes or other lines may be accommodated.

The embodiment of FIGS. 2-6 also has a narrower width dimension 130 than the embodiment of FIG. 1. Specifically, width dimension 130 of this embodiment can range from about 4.5″ to about 6.5″ with about 5.75″ being preferred. FIGS. 2 and 4 also illustrate nail holes 195 for placement of nails through flange to secure line set box 100 to wall 300.

In addition, FIG. 2 illustrates a further distinction between the embodiment of FIG. 1. Rather than having bottom 125 angled to meet back 120 as in FIG. 1, the embodiment of FIG. 2 has a bottom configured as an upper bottom piece 185 and a lower bottom piece 190. Upper bottom piece 185 and lower bottom piece 190 combine together to replace back 125 and join back 120 as shown more clearly in FIG. 6. The angles at which back 120, upper bottom piece 185 and a lower bottom piece 190 are joined may vary, although overall angle 122 is maintained as described above for FIG. 1. Having upper bottom piece 185 and lower bottom piece 190 provides more space in the back of line set box 100 for the line set and condensation drain, and also allows for a gentler arc in directing the line sets, voltage lines and drains to exit from the open front on box 100.

FIG. 5 illustrates the bottom of line set box 100, in which only upper bottom piece 185 and a lower bottom piece 190 can be seen from this view.

In conjunction with the disclosure of the line set box 100 of this invention is a method for providing an effective way for the refrigeration line set, condensation drain and low voltage wires to exit from the interior to the exterior of a building without using a fitting or being crushed, kinked or cut off after installation. The method comprises the steps of pre-cutting a square or rectangular hole in the outside wall of the building, before siding is added, and installing line set box 100 by nailing it onto the outside of the wall 300 using the nail flange 145. Cut outs 155 and 170 are then opened using an appropriate tool, such as a knife. Then, the refrigeration line set, low voltage wire and condensation drain from the above-installed air conditioner unit, are channeled down the inside of external wall 300, through cut outs 155 and 170, and into line set box 100. Specifically, the refrigeration line set is channeled through larger cut out 155, and is followed by low voltage wire, also through cut out 155. The condensation drain is channeled through smaller cut out 170. Once inside line set box 100, the ends of the refrigeration line set, condensation drain and low voltage wires are covered or capped, to protect them until they can be connected to the corresponding lines of the compressor unit of the air conditioner.

The preceding preferred embodiments are illustrative of the practice of the invention. It is to be understood, however, that other expedients known to those of skill in the art, or disclosed herein, may be employed without departing from the spirit of the invention or the scope of the claims. 

1. A system for receiving a refrigeration line set, low voltage wire and/or condensation drain, comprising: a rectangular or square-shaped box mounted in a pre-cut opening in a building wall, said box comprising a top side, a bottom side, a left side, a right side, a back side and an open side opposite said back side, wherein said box is mounted such that the back side of said box extends through said opening in said wall from the exterior to the interior of said wall, and said open side faces away from the exterior of said wall; one or more cut-out openings in said top side of said box for receiving said refrigeration line set, low voltage wire and/or condensation drain on the interior side of said wall; wherein said bottom side is directed upward and backward at an angle from the front of said box until it meets and is joined with said back side of said box forming an angle of greater than 90°,
 2. The system of claim 1, further comprising a flange located around the outside perimeter of said box for securing said box to said wall.
 3. The system of claim 2, wherein said angle of said bottom of said box directs said refrigeration line set, low voltage wire and/or condensation drain from the interior of said wall to the exterior of said wall.
 4. The system of claim 3, wherein said bottom side comprises an upper bottom piece and a lower bottom piece.
 5. A method for directing a refrigeration line set, condensation drain and/or low voltage wires from an air conditioner unit from the interior to the exterior of a building comprising the steps of: pre-cutting a square or rectangular hole in the external wall of the building, before siding is added; installing a rectangular or square-shaped box mounted in said pre-cut, said box comprising a top side, a bottom side, a left side, a right side, a back side and an open side opposite said back side, wherein said box is mounted such that the back side of said box extends through said opening in said wall from the exterior to the interior of said wall, and said open side faces away from the exterior of said wall; one or more cut-out openings in said top side of said box for receiving said refrigeration line set, low voltage wire and/or condensation drain on the interior side of said wall; wherein said bottom side is directed upward and backward at an angle from the front of said box until it meets and is joined with said back side of said box forming an angle of greater than 90°, opening said cut-out openings; channeling said refrigeration line set, low voltage wire and/or condensation drain down the inside said external wall through said cut out openings into said box; and directing the ends of said refrigeration line set, low voltage wire and/or condensation drain towards or through said open side of said box.
 6. The method of claim 5, further comprising the step of capping said ends of said refrigeration line set, low voltage wire and/or condensation drain.
 7. A receptacle box for directing a refrigeration line set, low voltage wire and/or condensation drain, from the interior to the exterior of a building, comprising: a top side, having one or more openings for receiving said refrigeration line set, low voltage wire and/or condensation drain from the interior of said building, a back side, an open side located opposite to said back side; a bottom side directed upward and backward at an angle from the front of said box until it meets and is joined with said back side of said box, forming an angle of greater than 90°, wherein said angle formed by said back side and said bottom side direct ends of said refrigeration line set, low voltage wire and/or condensation drain through said open side to the exterior of said building.
 8. The receptacle box of claim 7, further comprising a flange mounted around the outside periphery of said box for securing said box in a pre-cut opening in a wall of said building.
 9. The receptacle box of claim 7 wherein said bottom of said box comprises an upper bottom piece and a lower bottom piece. 